2011 Arctic Cat Prowler XT XTX XTZ ROV Service Repair Manual by 1636571

FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2011 Arctic Cat ROV (Recreational Off-Highway Vehicle) models (see cover). The complete manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections. Each section covers a specific vehicle component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. The service technician should become familiar with the operation and construction of each component or system by carefully studying this manual. This manual will assist the service technician in becoming more aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of serious personal injury or even death. A CAUTION identifies unsafe practices which may result in vehicle-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the vehicle. The symbol  NOTE: identifies supplementary information worthy of particular attention. The symbol  AT THIS POINT directs the technician to certain and specific procedures to promote efficiency and to improve clarity. At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred. All materials and specifications are subject to change without notice. Keep this manual accessible in the shop area for reference. Product Service and Warranty Department Arctic Cat Inc.

September 2010

Click on the blue text to go.

1 10

TABLE OF CONTENTS

Service Manual

Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the Table of Contents bookmarks on the left side of the screen, or click the blue text below. To return to this page, click the Manual Table of Contents button at the bottom of each page.

Prowler wler X XT 1 Prowler ro r XT X XTX TX Prowler P Pr ow wler XT XTZ

General Information/Specifications

Periodic Maintenance/Tune-Up

Engine/Transmission

Fuel/Lubrication/Cooling

Electrical System

Drive System

Suspension

Steering/Frame

Controls/Indicators

SHARE OUR PASSION.

SECTION 1 - GENERAL INFORMATION

TABLE OF CONTENTS General Specifications ............................................ 1-2 Torque Specifications .............................................. 1-2 Torque Conversions (ft-lb/N-m) ............................... 1-4 Tightening Torque (General Bolts) .......................... 1-4 Break-In Procedure ................................................. 1-4 Gasoline - Oil - Lubricant ........................................ 1-4 Genuine Parts ......................................................... 1-5 Preparation For Storage.......................................... 1-5 Preparation After Storage........................................ 1-6

1-1

STEERING COMPONENTS

General Specifications

Part

CHASSIS Dry Weight (approx)

(XT) (XTX) (XTZ)

Length (overall) Height (overall) Width (overall) Suspension Travel Brake Type Wheelbase Tire Size - XT/XTX

(front) (rear) Tire Size - XTZ (front) (rear) Tire Inflation Pressure - XT/XTX Tire Inflation Pressure - XTZ (front) (rear)

558 kg (1230 lb) 567 kg (1251 lb) 596 kg (1315 lb) 301.5 cm (118.7 in.) 201 cm (79 in.) 156.2 cm (61.5 in.) 25.4 cm (10 in.) Hydraulic 190 cm (75 in.) 26 x 9R-14 26 x 11R-14 27 x 9R-14 27 x 11R-14 0.70 kg/cm² (10 psi) 0.84 kg/cm² (12 psi) 0.84-1.41 kg/cm² (12-20 psi)

31 L (8.2 U.S. gal.) 2.9 L (3.0 U.S. qt) 3.3 L (3.5 U.S. qt) Front Differential Capacity 275 ml (9.3 fl oz)* Rear Drive Capacity 250 ml (8.5 fl oz)* Engine Oil Capacity (H1) 2.5 L (2.6 U.S. qt) - Overhaul 1.9 L (2.0 U.S. qt) - Change (H2) 2.6 L (2.45 U.S. qt) - Overhaul 2.1 L (2.25 U.S. qt) - Change Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) Arctic Cat ACX All Weather Synthetic Front Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Belt Width 35.0 mm (1.38 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (4)

Specifications subject to change without notice. * Visible at plug threads.

Torque Specifications NOTE: Torque specifications have the following tolerances:

34 49 49

Rack and Pinion Assembly - Frame XT

Rack and Pinion Assembly - Frame XTX/XTZ

Tie Rod** - XT

Rack

Tie Rod** - XTX/XTZ

Rack

52 37 30 10 35 11 31 11

70 50 41 14 48 15 42 15

Steering Wheel Shaft

Steering Wheel Shaft***

Intermediate Shaft (Upper)

Intermediate Shaft (Lower)*** - XT

Steering Pinion Shaft

Tie Rod End**

Knuckle

Jam Nut

Tie Rod End

EPS Assembly - XTX/XTZ

Frame

EPS Assembly - XTX/XTZ

Rack Coupler

Steering Shaft Housing (6 mm) - XTX/XTZ

Frame

Steering Shaft Housing (8 mm) - XTX/XTZ

Frame

33 35 33 35

45 48 45 48 45 45 27

SUSPENSION COMPONENTS (Front) A-Arm

Frame

Knuckle

Ball Joint

Shock Absorber

Frame/Upper A-Arm

Knuckle

A-Arm

SUSPENSION COMPONENTS (Rear) Sway Bar Bracket

Frame

A-Arm

Frame

Shock Absorber (Lower) XT/XTX

Lower A-Arm

33 33 20

Shock Absorber (Lower) XTZ

Frame

Shock Absorber (Upper)

Frame

Knuckle

A-Arm

Cargo Box Hinge

Cargo Box Frame

33 35 20 20 15 60 in.-lb

45 48 27 27 20 7 20 27 27 34 27 27 27 27 27 27

Cargo Box

Cargo Box Frame

Latch Pivot Bushing

Cargo Box Frame

Latch Striker

Cargo Box Liner

BRAKE COMPONENTS

0-15

±20%

Brake Hose

16-39

±15%

Master Cylinder

Frame

40+

±10%

Caliper Holder****

Knuckle

Brake Caliper****

Gear Case Housing

Brake Caliper

Rear Drive Housing

Driveline

Rear Drive Input Flange

Parking Brake Actuator Lever

Caliper

15 20 20 25 20 20 20 20 20

Parking Brake Caliper Assembly

Rear Drive Housing

Brake Disc**

Hub

Torque (ft-lb)

Tolerance

Brake Hose

Caliper Master Cylinder

EXHAUST COMPONENTS Part

Part Bolted To

Exhaust Pipe

Cylinder Head

Spark Arrester

Muffler

Torque ft-lb

N-m

20 27 48 in.-lb 5

ELECTRICAL COMPONENTS Coil*

Frame

Ground Wire

Engine

8 8

11 11

20 20

27 27

8 8

11 11

CHASSIS/ROPS ASSEMBLY Shift Lever*

Shift Axle Bracket

Front/Rear ROPS Tube

Arm Rest/Steering Post Support

Top ROPS Support

Front/Rear ROPS Tubes

Rear ROPS Tube

Lower ROPS Support

1-2

N-m

25 36 36

Steering Wheel**

Intermediate Shaft (lower) - EPS Input Shaft XTX/XTZ

(H1) (H2)

Torque ft-lb

Intermediate Shaft Coupler Intermediate Shaft

MISCELLANY Gas Tank Capacity Coolant Capacity

Part Bolted To

* w/Blue Loctite #243 ** w/Red Loctite #271

*** w/Green Loctite #270 **** w/“Patch-Lock”

DRIVE TRAIN COMPONENTS Part

Part Bolted To

Rear Differential/Gear Case

Frame

Drive Coupler (Front)

Drive Flange

Front Engine Mounting Bracket

Frame

Rear Engine Mounting Bracket Frame Engine Mounting Through-Bolt Frame Front Differential

Frame/Differential Bracket

Rear Output Flange

Rear U-Joint Flange

Input Shaft Assembly

Gear Case Housing

Pinion Housing

Differential Housing

Differential Housing Cover*** Differential Housing Drive Bevel Gear Nut***

Shaft

Lock Collar

Differential Housing

Hub Nut

Front/Rear Shaft/Axle (min)

Oil Drain Plug

Front Differential - Rear Drive

Oil Fill Plug

Front Differential - Rear Drive

Oil Drain Plug

Engine

Wheel (Aluminum)

Hub

Wheel (Steel)

Hub

Front Input Drive Flange

Front U-Joint

ENGINE/TRANSMISSION - H2 Torque

38 40 45

48 54 61

45 40 38 40 23 23 23 87 125 200

61 54 52 54 31 31 31 118 170 272

45 in.- 5 lb 16 22 16 80 45 20

22 108 61 27

221 8

300 11

ENGINE/TRANSMISSION - H1 Clutch Shoe**

Crankshaft

Clutch Cover/Housing Assembly

Crankcase

Crankcase Half (6 mm)

Crankcase Half

Crankcase Half (8 mm)

Crankcase Half

Cylinder Head (Cap Screw)

Crankcase

Cylinder Head Nut (6 mm)

Cylinder

Cylinder Head Nut (8 mm)

Cylinder

Valve Cover

Cylinder Head

Driven Pulley Nut

Driveshaft

Movable Drive Face Nut**

Driveshaft

Ground Wire

Engine

Magneto Cover

Crankcase

Tappet Cover

Valve Cover

Crankshaft Spacer

Crankshaft

Oil Pump Cover**

Crankcase

Oil Pump Drive Gear**

Crank Balancer Shaft

Output Shaft Flange Nut

Output Shaft**

Outer Magneto Cover

Magneto Cover

Magneto Rotor Nut**

Crankshaft

Cam Sprocket**

Camshaft

Speed Sensor Housing

Crankcase

V-Belt Cover

Crankcase

Output Yoke Nut

Secondary Driven Output Shaft

Ouput Shaft Flange Yoke/Nut Output Shaft** Secondary Shaft Bearing Housing

Crankcase Half

Stator Coil*

Magneto Cover

Intake Boot Clamp

Intake Boot

Part

ft-lb N-m

10 14 20 27 40 54 8 11 18 24 8.5 11.5 80 109 165 224 8 11 8 11 9 12 28 38 8 11 62 84 62 84 8 11 105 143 11 15 8 11 8 11 74 100 59 28

Part Bolted To

Torque ft-lb N-m

Clutch Shoe**

Crankshaft

Clutch Cover/Housing Assembly

Crankcase

221 8

300 11

Lower Crankcase Cover (6 mm)

Crankcase

Lower Crankcase Cover (8 mm)

Crankcase

Crankcase Half

Cylinder Head (Cap Screw)

Crankcase

Cylinder Head Nut (6 mm)

Cylinder

Cylinder Head Nut (8 mm)

Cylinder

Valve Cover

Cylinder Head

Driven Pulley Nut**

Driveshaft

Movable Drive Face Nut**

Driveshaft

Ground Wire

Engine

Magneto Cover

Crankcase

Tappet Cover

Valve Cover

Crankshaft Spacer

Crankshaft

Oil Pump Drive Gear**

Crank Balancer Shaft

Output Shaft Flange Yoke/Nut Output Shaft** Outer Magneto Cover

Magneto Cover

Rotor/Flywheel Nut**

Crankshaft

Cam Sprocket**

Camshaft

CVT Cover

Crankcase

Secondary Drive Gear Nut**

Secondary Drive Output Shaft

Oil Filter Cover

Crankcase

Speed Sensor Housing

Crankcase

Shift Cam Stopper

Crankcase

Shift Cam Stopper Spring

Shift Cam Stopper

Shift Cam Plate

Shift Cam Shaft

Shifter Housing

Crankcase

Starter Motor

Crankcase

V-Belt Cover

Crankcase

Oil Pump Cover**

Crankcase

Oil Strainer Cap

Crankcase

Stator Coil*

Magneto Cover

Intake Boot Clamp

Intake Boot

8 11 38 52 8 11 18 24 8.5 11.5 80 109 165 224 8 11 8 11 9 12 28 38 62 84 59 80 8 11 105 143 11 15 8 11 74 100 8 8 8 8 8 8 8 8 8 8 8.5 30 in.lb

11 11 11 11 11 11 11 11 11 11 11.5 3.4

* w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #270

80 38

8.5 11.5 30 in.- 3.4 lb

1-3

Torque Conversions (ft-lb/N-m)

Break-In Procedure

ft-lb

N-m

ft-lb

N-m

ft-lb

N-m

ft-lb

N-m

1.4

35.4

69.4

103.4

2.7

36.7

70.7

104.7

4.1

38.1

72.1

106.1

5.4

39.4

73.4

107.4

6.8

40.8

74.8

108.8

8.2

42.2

76.2

110.2

9.5

43.5

77.5

111.5

10.9

44.9

78.9

112.9

12.2

46.2

80.2

114.2

13.6

47.6

81.6

115.6

117

16.3

50.3

84.3

118.3

17.7

51.7

85.7

119.7

121

20.4

54.4

88.4

122.4

21.8

55.8

89.8

123.8

23.1

57.1

91.1

125.1

24.5

58.5

92.5

126.5

25.8

59.8

93.8

127.8

27.2

61.2

95.2

129.2

28.6

62.6

96.6

130.6

29.9

63.9

97.9

131.9

31.3

65.3

99.3

133.3

32.6

66.6

100.6

134.6

102

100

136

Tightening Torque (General Bolts)

Type of Bolt (Conventional or 4 Marked Bolt)

(7 Marked Bolt)

1-4

Thread Diameter A (mm)

Tightening Torque

12-36 in.-lb

36-60 in.-lb

7-11 ft-lb

16-25 ft-lb

24-48 in.-lb

6-8 ft-lb

13-20 ft-lb

29-43 ft-lb

A new vehicle and an overhauled engine require a “break-in” period. The first 10 hours (or 200 miles) are most critical to the life of this vehicle. Proper operation during this break-in period will help assure maximum life and performance from the vehicle. During the first 10 hours (or 200 miles) of operation, always use less than 1/2 throttle. Varying the engine RPM during the break-in period allows the components to “load” (aiding the mating process) and then “unload” (allowing components to cool). Although it is essential to place some stress on the engine components during break-in, care should be taken not to overload the engine too often. Do not pull a trailer or carry heavy loads during the 10-hour break-in period. When the engine starts, allow it to warm up properly. Idle the engine several minutes until the engine has reached normal operating temperature. Do not idle the engine for excessively long periods of time. During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in. After the completion of the break-in period, the engine oil and oil filter should be changed. Other maintenance after break-in should include checking of all prescribed adjustments and tightening of all fasteners (see Periodic Maintenance Chart in Section 2).

Gasoline - Oil - Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas, oxygenates (either ethanol or MTBE) are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol, 5% methane, or 5% MTBE are acceptable gasolines. When using ethanol blended gasoline, it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system.

CAUTION Do not use white gas. Only Arctic Cat approved gasoline additives should be used.

Thank you very much for your reading. Please Click Here Then Get More Information. NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.

RECOMMENDED ENGINE/ TRANSMISSION OIL

FILLING GAS TANK ! WARNING

CAUTION Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation. Also, not recommended are racing, vegetable, non-detergent, and castor-based oils.

Always fill the gas tank in a well-ventilated area. Never add fuel to the gas tank near any open flames or with the engine running. DO NOT SMOKE while filling the gas tank.

The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil, which has been specifically formulated for use in this Arctic Cat engine. Although Arctic Cat ACX All Weather synthetic engine oil is the only oil recommended for use in this engine, use of any API certified SM 5W-50 oil is acceptable.

ATV0049B

Since gasoline expands as its temperature rises, the gas tank must be filled to its specified capacity only. Expansion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area.

! WARNING OILCHARTI

RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of the Arctic Cat vehicle front differential and rear drive.

Do not overflow gasoline when filling the gas tank. A fire hazard could materialize. Always allow the engine to cool before filling the gas tank.

Tighten the gas tank cap securely after filling the tank.

! WARNING Do not over-fill the gas tank.

Genuine Parts

CAUTION Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive damage.

When replacement of parts is necessary, use only genuine Arctic Cat parts. They are precision-made to ensure high quality and correct fit. Refer to the appropriate Illustrated Parts Manual for the correct part number, quantity, and description.

Preparation For Storage CAUTION Prior to storing the vehicle, it must be properly serviced to prevent rusting and component deterioration.

1. Clean the seat cushion (cover and base) with a damp cloth and allow it to dry. 1-5

2. Clean the vehicle thoroughly by washing dirt, oil, grass, and other foreign matter from the entire vehicle. Allow it to dry thoroughly. DO NOT get water into any part of the engine or air intake. 3. Either drain the gas tank or add Fuel Stabilizer to the gas in the gas tank. Remove the air filter housing cover and air filter. Start the engine and allow it to idle. Using Arctic Cat Engine Storage Preserver, rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds; then stop the engine. Install the air filter and housing cover.

CAUTION If the interior of the air filter housing is dirty, clean the area before starting the engine.

4. Plug the exhaust hole in the exhaust system with a clean cloth. 5. Apply light oil to the plungers of the shock absorbers. 6. Tighten all nuts, bolts, cap screws, and screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, cap screws, and bolts are tightened to specifications. 7. Fill the cooling system to the bottom of the stand pipe in the radiator neck with properly mixed coolant. 8. Disconnect the battery cables; then remove the battery, clean the battery posts and cables, and store in a clean, dry area. 9. Store the vehicle indoors in a level position.

CAUTION Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the vehicle causing rusting.

Preparation After Storage Taking the vehicle out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. 1. Clean the vehicle thoroughly. 2. Clean the engine. Remove the cloth from the exhaust system. 3. Check all control wires and cables for signs of wear or fraying. Replace if necessary. 4. Change the engine/transmission oil and filter. 5. Check the coolant level and add properly mixed coolant as necessary. 6. Charge the battery; then install. Connect the battery cables.

CAUTION The ignition switch must be in the OFF position prior to installing the battery or damage may occur to the ignition system.

CAUTION Connect the positive battery cable first; then the negative.

7. Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, and headlight aim; adjust or replace as necessary. 8. Tighten all nuts, bolts, cap screws, and screws making sure all calibrated nuts, cap screws, and bolts are tightened to specifications. 9. Check tire pressure. Inflate to recommended pressure as necessary. 10. Make sure the steering moves freely and does not bind. 11. Check the spark plug(s). Clean or replace as necessary.

1-6

SECTION 2 PERIODIC MAINTENANCE/TUNE-UP

TABLE OF CONTENTS Periodic Maintenance Chart .................................... 2-2 Periodic Maintenance.............................................. 2-3 Lubrication Points.................................................... 2-3 Air Filter ................................................................... 2-3 Valve/Tappet Clearance (H1)................................... 2-4 Valve/Tappet Clearance (H2)................................... 2-4 Testing Engine Compression................................... 2-6 Spark Plug(s) .......................................................... 2-6 Muffler/Spark Arrester ............................................. 2-7 Engine/Transmission Oil - Filter............................... 2-7 Front Differential - Rear Drive Lubricant.................. 2-8 Driveshaft/Coupling ................................................. 2-9 Nuts/Bolts/Cap Screws............................................ 2-9 Headlight/Taillight-Brakelight ................................... 2-9 Shift Lever ............................................................. 2-10 Hydraulic Brake System ........................................ 2-10 Parking Brake ........................................................ 2-12 Burnishing Brake Pads .......................................... 2-15 Checking/Replacing V-Belt .................................... 2-15 Troubleshooting Brake System.............................. 2-17 2-1

A = Adjust C = Clean R = Replace

Periodic Maintenance Chart

Item Battery

Initial Service After Break-In Every (First Month Day or 100 Mile) I

Every Month or Every 100 Miles

I = Inspect L = Lubricate T = Tighten

Every 3 Months or Every 300 Miles

Every 6 Months or Every 500 Miles

As Needed

Fuses

C I

Air Filter/Drain Tube

Valve/Tappet Clearance

R I

Engine Compression Spark Plug(s)

Every Year or Every 1500 Miles

A I

Muffler/Spark Arrester Gas Hoses

Throttle Cable Ends/Accelerator Pedal Pivot

Engine-Transmission Oil Level

R (4000 Mi or 18 Mo)

R R (2 Yrs)

C-L

A-R

Engine-Transmission Oil/Filter

Oil Strainer

Front Differential - Rear Drive Lubricant

Tires/Air Pressure

Steering Components

V-Belt

Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows)

Nuts/Bolts/Cap Screws

A R*/R**/R***

R I***

R (4 Yrs) R I

R l

Ignition Timing

Headlight/Taillight-Brakelight

Switches

Gauges/Indicators

Frame/Welds

Shift Lever

A-L R

Electrical Connections

Complete Brake System (Hydraulic & Parking)

Brake Pads

Brake Fluid

R (2 Yrs)

Brake Hoses

R (4 Yrs)

Coolant/Cooling System

Wheel Lug Nuts

R (2 Yrs) T

* Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change and strainer inspection interval can be increased to every 1,000 miles or every year.

2-2

Periodic Maintenance This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat ROV. NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission. NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions.

CLEANING AND INSPECTING FILTER CAUTION Failure to inspect the air filter frequently if the vehicle is used in dusty, wet, or muddy conditions can damage the engine.

1. Remove the seats; then remove the center console. 2. Unsnap the four fasteners securing the air cleaner housing cover and remove the cover. 3. Remove the air filter frame (A); then remove the foam filter element (B).

NOTE: Critical torque specifications are located in Section 1.

SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section. Refer to the current Special Tools Catalog for the appropriate tool description. Description

p/n

Compression Tester Kit

0444-213

Oil Filter Wrench

0644-389

Timing Light

0644-296

Valve Clearance Adjuster

0444-255

NOTE: Special tools are available from the Arctic Cat Service Parts Department.

Lubrication Points It is advisable to lubricate certain components periodically to ensure free movement. Apply light oil to the components using the following list as reference. A. Accelerator Pedal Pivot/Cable Ends B. Brake Pedal Pivot C. Parking Brake Cable Ends

PR576A

4. Fill a wash pan larger than the filter with a non-flammable cleaning solvent; then dip the filter in the solvent and wash it. NOTE: Foam Filter Cleaner and Foam Filter Oil are available from Arctic Cat.

5. Dry the filter. 6. Put the filter in a plastic bag; then pour in air filter oil and work the filter. Reattach the filter to the filter screen. NOTE: Carefully squeeze excessive oil from the filter element. Do not twist foam to remove oil.

CAUTION A torn air filter can cause damage to the vehicle engine. Dirt and dust may get inside the engine if the element is torn. Carefully examine the element for tears before and after cleaning it. Replace the element with a new one if it is torn.

7. Clean any dirt or debris from inside the air cleaner. Be sure no dirt enters the throttle body.

D. Shift Cable

Air Filter Use the following procedure to remove the filter and inspect and/or clean it.

8. Place the foam filter in the air filter housing; then position the filter frame on top. 9. Install the air filter housing cover and secure with the retaining clips; then install the center console and seats making sure the seats lock securely.

2-3

CHECKING AND CLEANING DRAINS 1. Inspect one-way drains beneath the main housing for debris and for proper sealing. 2. Replace any one-way drain that is cracked or shows any signs of hardening or deterioration.

CAUTION The one-way drain to the left is the clean air section of the filter housing. Any leak of this drain will allow dirt into the engine intake causing severe engine damage.

3. Wipe any accumulation of oil or gas from the filter housing and one-way drains.

Valve/Tappet Clearance (H1) To check and adjust valve/tappet clearance, use the following procedure. NOTE: The engine must be cold for this procedure. NOTE: The seats, center console, spark plug, and air filter housing must be removed for this procedure.

1. Remove the spark plug and timing inspection plug; then remove the tappet covers (for more detailed information, see Section 3 - Servicing Top-Side Components). 2. Rotate the crankshaft to the TDC position on the compression stroke. NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them.

Feeler Gauge Procedure Using a feeler gauge, check each valve/tappet clearance. If clearance is not within specifications, loosen the jam nut and rotate the tappet adjuster screw until the clearance is within specifications. Tighten each jam nut securely after completing the adjustment.

CAUTION The feeler gauge must be positioned at the same angle as the valve and valve adjuster for an accurate measurement of clearance. Failure to measure the valve clearance accurately could cause valve component damage. VALVE/TAPPET CLEARANCE Intake

0.1016 mm (0.004 in.)

Exhaust

0.1524 mm (0.006 in.)

CC007D

Valve Adjuster Procedure A. Place the Valve Clearance Adjuster onto the jam nut securing the tappet adjuster screw; then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw. B. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut; then rotate the tappet adjuster screw clockwise until friction is felt. C. Align the valve adjuster handle with one of the marks on the valve adjuster dial. D. While holding the valve adjuster handle in place, rotate the valve adjuster dial counterclockwise until proper valve/tappet clearance is attained. NOTE: Refer to the appropriate specifications in Feeler Gauge Procedure sub-section for the proper valve/tappet clearance. NOTE: Rotating the valve adjuster dial counterclockwise will open the valve/tappet clearance by 0.05 mm (0.002 in.) per mark.

E. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely with the valve adjuster handle. 3. Install the spark plug; then install the timing inspection plug. 4. Place the two tappet covers with O-rings into position. Tighten the cap screws securely.

Valve/Tappet Clearance (H2) To check and adjust valve/tappet clearance, use the following procedure. NOTE: The engine must be cold for this procedure. NOTE: The seats, center console, spark plugs, and air filter housing must be removed for this procedure.

2-4

1. Remove the spark plugs and timing inspection plug; then remove the tappet covers (for more detailed information, see Section 3 - Servicing Top-Side Components).

B. Rotate the engine 270° to the TDC position of the rear cylinder; then repeat step A. The stamped “R” must be visible.

NOTE: Remove the crankshaft end cap and install the special cap screw (left-hand threads) to rotate the engine.

2. Rotate the crankshaft to the TDC position on the compression stroke of the front cylinder. The stamped “F” must be visible.

GZ059

NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them.

Feeler Gauge Procedure A. Using a feeler gauge, check each valve/tappet clearance. If clearance is not within specifications, loosen the jam nut and rotate the tappet adjuster screw until the clearance is within specifications. Tighten each jam nut securely after completing the adjustment.

0.1016 mm (0.004 in.)

Exhaust

0.1524 mm (0.006 in.)

B. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut; then rotate the tappet adjuster screw clockwise until friction is felt. C. Align the valve adjuster handle with one of the marks on the valve adjuster dial. D. While holding the valve adjuster handle in place, rotate the valve adjuster dial counterclockwise until proper valve/tappet clearance is attained. NOTE: Refer to the appropriate specifications in Feeler Gauge Procedure sub-section for the proper valve/tappet clearance. NOTE: Rotating the valve adjuster dial counterclockwise will open the valve/tappet clearance by 0.05 mm (0.002 in.) per mark.

E. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely with the valve adjuster handle. F. Rotate the engine 270° to the TDC position of the rear cylinder; then repeat steps A-D for the rear cylinder. 3. Install the spark plugs and timing inspection plug; then remove the cap screw and install the crankcase end cap. 4. Place the two tappet covers into position making sure the proper cap screws are with the proper cover. Tighten the cap screws securely.

CC007DC

2-5